Modular structural composite beam

Abstract

A modular fiber reinforced plastic flange for a structural composite beam which comprises a body formed of a plurality of elongate elements arranged in an array, wherein the dimensions of the body are substantially determined by the number and arrangement of the elongate elements in the array, and a skin member at least partially surrounding the array. Also, a structural composite beam comprising the modular fiber reinforced plastic flange and a shear web connected to the skin member of the modular flange. A method of making the modular flange and beams, and a kit of parts for making the modular flange are also disclosed.

What is claimed is: 
     
       1. A modular fibre reinforced plastic flange for a structural composite beam comprising:
 a modular body formed of a plurality of pre-cured elongate elements each formed from a composite material, the elongate elements extending longitudinally the length of the beam, the elongate elements being arranged side-by-side, on top of one another, or side-by-side and on top of one another in an array such that the longitudinal axes of the elongate elements are parallel to one another, wherein the dimensions of the modular body are substantially determined by the number and arrangement of the elongate elements in the array, 
 at least one of the elongate elements being a first elongate element made of a first composite material comprising a first material; 
 at least one of the elongate elements being a second elongate element made of a second composite material comprising a second material, wherein the first material is different from the second material, and wherein the first and second elements are the same size and shape in cross-section; and 
 a modular skin member being configurable to accommodate a variable number or arrangement, or a variable number and arrangement, of elongate elements in the array, the modular skin member extending longitudinally along a substantial portion of the length of a plurality of the elongate elements in the array. 
 
     
     
       2. A modular flange as claimed in  claim 1 , wherein the skin member fully surrounds the array of elongate composite elements. 
     
     
       3. A modular flange as claimed in  claim 2 , wherein the skin member comprises first and second skin elements, the first skin element having a concave form and the second skin element being arranged to fit within the first skin element. 
     
     
       4. A modular flange as claimed in  claim 1 , further comprising at least one reinforcement layer at least partially located within the array of elongate elements. 
     
     
       5. A structural composite beam comprising:
 a modular flange as claimed in  claim 1 ; and 
 a shear web connected to the skin member of the modular flange. 
 
     
     
       6. A structural composite beam as claimed in  claim 5 , wherein the shear web comprises a structural core located between two composite material layers. 
     
     
       7. A method of forming a modular fibre reinforced plastic flange for a structural composite beam comprising:
 forming a modular body from a plurality of pre-cured elongate elements each formed from a composite material, the elongate elements extending longitudinally the length of the beam, the elongate elements being arranged side-by-side, on top of one another, or side-by-side and on top of one another in an array such that the longitudinal axes of the elongate elements are parallel to one another, wherein the dimensions of the modular body are substantially determined by the number and arrangement of the elongate elements in the array, 
 at least one of the elongate elements being a first elongate element made of a first composite material comprising a first material; 
 at least one of the elongate elements being a second elongate element made of a second composite material comprising a second material, wherein the first material is different from the second material, and wherein the first and second elements are the same size and shape in cross-section; and 
 connecting a modular skin member to the body, the modular skin member being configurable to accommodate a variable number or arrangement, or a variable number and arrangement, of elongate elements in the array, the modular skin member extending longitudinally along a substantial portion of the length of a plurality of the elongate elements in the array. 
 
     
     
       8. A method of forming a modular flange as claimed in  claim 7 , further comprising:
 selecting a number and arrangement of elongate composite elements to define the dimensions of the body; and 
 selecting a skin member which is sized to substantially fit the dimensions of the body. 
 
     
     
       9. A method of forming a modular flange as claimed in  claim 8 , wherein the skin member comprises first and second skin elements, the first skin element having a concave form and the second skin element being arranged to fit within the first skin element; the method further comprising:
 locating the body within the first skin element; and 
 locating the second skin element within the first skin element to form a skin member which fully surrounds the body. 
 
     
     
       10. A method of forming a structural composite beam comprising:
 using the method of  claim 7  to form a modular flange; and 
 connecting at least one shear web to the skin member of the modular flange. 
 
     
     
       11. A method of forming a structural composite beam as claimed in  claim 10 , wherein each component part of the structural composite beam is made in a continuous production process. 
     
     
       12. A method as claimed in  claim 10 , wherein, before forming the body, the skin member of the modular flange and the at least one shear web of the structural composite beam are in a cured or semi-cured state and exhibit their final form. 
     
     
       13. A method of forming a modular flange as claimed in  claim 7 , wherein each component part of the modular flange is made in a continuous production process. 
     
     
       14. A kit of parts for forming modular fibre reinforced plastic flanges comprising:
 a plurality of pre-cured elongate elements suitable for forming a modular body comprising the plurality of elongate elements, each of the elongate elements formed from a composite material, the elongate elements extending longitudinally the length of the beam, the elongate elements being arranged side-by-side, on top of one another, or side-by-side and on top of one another in an array, wherein the longitudinal axes of the elongate elements are parallel to one another, and wherein the dimensions of the modular body are substantially determined by the number and arrangement of the elongate elements in the array, 
 at least one of the elongate elements being a first elongate element made of a first composite material comprising a first material; 
 at least one of the elongate elements being a second elongate element made of a second composite material comprising a second material, wherein the first material is different from the second material, and wherein the first and second elements are the same size and shape in cross-section; and 
 a plurality of modular skin members, wherein the plurality of modular skin members are configurable to accommodate a variable number or arrangement, or a variable number and arrangement, of elongate elements in the array, the modular skin members extending longitudinally along a substantial portion of the length of a plurality of the elongate elements in the array. 
 
     
     
       15. A kit of parts as claimed in  claim 14 , wherein the elongate composite elements and skin members are in a cured or semi-cured state and exhibit their final form.